Compressible mattress

ABSTRACT

In an implementation a compressible mattress is provided that may be compressed at a manufacturing location and inserted into packaging; the packaging, maintaining the compressed state of the compressed mattress. The compressed mattress may be shipped in the compressed state within the packaging to a distributor or retail store for display and sale. After sale and transport to a customer location in the compressed state, the packaging may be removed and the mattress decompresses and expands until it reaches an expanded form.

TECHNICAL FIELD

The present disclosure relates to mattresses, and in particular crib mattresses.

BACKGROUND

Mattresses are bulky objects, which are costly to ship, store, or display for sale. Their size typically makes it uneconomical to manufacture mattresses far from the customer location, as shipping costs can make the sale cost prohibitive. Similarly, the cost to store and display mattresses at the retail location typically restricts their distribution to specialised retailers. Crib mattresses in particular are smaller value items, but have similarly large built-in costs for shipping, storing or displaying the mattresses for sale, that may be disproportionate to the value of the actual item.

There is a need for a mattress and a method of making a mattress that is less costly to ship, store and display. In particular, there is a need for a mattress that may be manufactured in a compressed, highly compact form, transported in the compact form, displayed and retailed in the compact form, and then expandable at the customer location into an expanded form that has standard mattress dimensions and performance. In an aspect, there is a need for a crib mattress that may be transported and displayed in a smaller, compact form factor to reduce the costs of shipment and retail, and ease the purchase and conveyance of the crib mattress.

SUMMARY

In an implementation a compressible mattress is provided that may be compressed at a manufacturing location and inserted into packaging. The packaging maintaining the compressed state of the compressed mattress. In some aspects, the compressed mattress may be further compacted and stored within a container that secures the mattress in its compacted state. The compressed mattress may be shipped in the compressed state within the packaging to a distributor or retail store for display and sale. After sale and transport to a customer location in the compressed state, the packaging may be removed and the mattress decompresses and expands until it reaches an expanded form.

A variety of mattress shapes and form factors may be provided. The mattress may include a waterproof protective layer to protect the mattress from liquids. The mattress may include a second outer protective layer over the waterproof protective layer. The mattress may include a coloured protective covering. Where the second outer protective layer is provided, it may comprise the coloured protective covering layer.

In an implementation, a method is provided for manufacturing a compressible mattress. The method may comprise: boring a plurality of holes through a thickness of a foam core (in an aspect, the holes being axially aligned with a compressing direction of the foam core) to produce a compressible mattress; inserting the mattress into an open end of a flexible-walled air tight packaging; compressing the mattress and packaging in the compressing direction; and, sealing the open end of the flexible air tight packaging to produce a compressed mattress. In an aspect, the mattress further comprises a protection layer over the bored foam core, wherein the method further comprises, before the foam mattress is inserted into the open end of the packaging, wrapping the bored foam core with a protection layer (the protection layer may comprise a waterproof breathable fabric) to produce the compressible mattress.

In an aspect, the implementation may further comprise compacting the compressed mattress by rolling or folding the compressed mattress to fit within a container, such as a box or plastic wrap, which secures the compacted mattress in its compact form. In an aspect, the container may comprise a decorative layer for presentation, for instance on a retail shelf In an aspect the packaging may comprise the decorative layer for presentation, and the container securing the compacted mattress may comprise a clear-walled container, ribbon, adhesive, string, or similar means that may secure the compacted mattress in its compact form and still display the decorative packaging.

In an aspect, the compressing may comprise placing the flexible air tight packaging containing the mattress between platens of a press, and pressing the platens of the press towards one another to compress the flexible air tight packaging and the mattress. In the aspect, the action of the platens compresses and evacuates the flexible air tight packaging.

In an aspect, after wrapping the bored foam core with the protective layer, the method further comprises wrapping an outer protective layer over the protective layer, before inserting the mattress into the open end of the flexible air tight packaging.

FIGURES

FIG. 1 illustrates a foam core.

FIG. 2 illustrates a perforation operation on the foam core.

FIG. 3 illustrates a perforated foam core after the operation of FIG. 2.

FIG. 4 illustrates a cut away view of an embodiment of the compressible mattress.

FIG. 5 illustrates the compressible mattress after insertion in a packaging.

FIG. 6 illustrates a compressing operation on the mattress and packaging.

FIG. 7 illustrates the compressed mattress and packaging in a compressed state.

FIG. 8 illustrates a rolling operation being performed on the compressed mattress and packaging of FIG. 7.

FIG. 9 illustrates a rolled compressed mattress within a container after the operation of FIG. 8.

DETAILED DESCRIPTION

Referring to FIG. 1, a foam core 10 for a compressible mattress is illustrated. The foam core 10 may be cut from larger bulk foam stock into the final form factor of the mattress. The foam is a standard foam used for foam mattresses in the industry. A density of the foam may be selected to provide for selected mattress firmness, as is known. Due to the operations below, however, the density selected for the compressible mattress may provide for a slightly different firmness from a regular foam mattress. Accordingly, the density may be selected to provide for a desired firmness after the holing operation described below. For instance, the density of the foam core 10 may be slightly higher than that required for a standard foam mattress, to achieve a desired mattress firmness after the holing operation.

In the embodiment illustrated in FIG. 1, the foam core 10 has been cut into a standard mattress shape. The size and dimensions of the foam core 10 is selected based upon the intended end use, and typically conforms to several standard form factors used throughout the industry. The foam core 10 may be cut into non-standard shapes and sizes, including cylinders, wedges, and other shapes, depending upon the intended end use.

In the case of a standard crib mattress, the size of the foam core 10 would be about 27 ⅝″-28 ⅝″ wide, and 51 ¾″-53″ long, as is currently the standard in the industry. The thickness of foam core 10 may vary, but will typically be provided within a range of 4″-6″ for a crib mattress.

Referring to FIG. 2, a perforating or holing machine 100 is illustrated with the foam core 10. The perforating machine 100 includes a number of pins or spikes 105 that may be lowered and pressed through the body of the foam core 10 to bore a plurality of holes through the foam core 10. The hole pattern created by the pins 105 may be regularly spaced to produce an even distribution of holes across the face of the foam core 10. In an aspect, for a standard-sized crib mattress, approximately 80-160 holes may be bored through the face of the foam core 10. In an aspect, the holes are bored clear through the mattress thickness.

In an implementation, a diameter of the holes may be within a diameter range of 8 mm-20 mm. In an aspect, the diameter may be within a diameter range of 10 mm-15 mm. In an aspect, the diameter may be within a diameter range of 12-13 mm.

In the embodiment of FIG. 2, the plurality of holes are bored through a face of the foam core 10. The axis of the each of the plurality of holes aligned with an intended compressing direction of a compressive force to be applied to the compressible mattress.

In an embodiment, the plurality of holes may be aligned at right angles to an intended compressing direction of the compressive force. For instance, in an aspect the form factor may comprise a cylindrical foam core, not shown in the Figures, with one or more holes bored through the cylindrical foam core approximately parallel to a central axis of the cylinder. In an aspect, the bored cylindrical foam core may be compressed in a compressing direction roughly perpendicular to the axis of the cylinder and the bored hole(s).

Referring to FIG. 3, the foam core 10 is illustrated after the perforation operation of FIG. 2. In the embodiment, a plurality of holes 15 evenly spaced across a face of the foam core 10 are illustrated. In an aspect, the perforated foam core 10 comprises a compressible mattress.

Referring to the embodiment of FIG. 4, an embodiment of a compressible mattress 30 is illustrated. In the embodiment of the mattress 30, the perforated foam core 10 is illustrated assembled with a protection layer 20 (“inner layer”) that is resistant to penetration by water or other liquids, but is air permeable. In an aspect, the protection layer 20 may comprise a waterproof breathable fabric. While the compressible mattress may comprise only the foam core 10 with the plurality of holes 15, the embodiment of FIG. 4 provides a layer of protection to protect the foam core 10 from liquids or moisture. Implementations that may comprise a crib mattress, for instance, protection layer 20 provides a barrier that prevents the foam core 10 from absorbing fluids, including bodily fluids. In an aspect, the protection layer 20 may be permanently secured over the foam core 10, for instance by stitching, heat sealing, adhesive, zipper, or other known means for affixing and sealing a waterproof breathable fabric.

As illustrated in the implementation of FIG. 4, the mattress 30 may further comprise an air permeable outer protective layer 25 wrapped over the protection layer 20.

The outer protective layer 25 may comprise, for instance, a coloured or patterned fabric layer. In some embodiments, the outer protective layer 25 may comprise a water resistant fabric to facilitate cleaning.

In an aspect, the outer protective layer 25 may be removably secured over the foam core 10 and protective layer 20 to facilitate removal for cleaning, for instance using a zipper, Velcro™, buttons, or other known means. In an aspect the outer protective layer 25 may be permanently secured over the foam core 10 and protective layer, for instance by stitching. In the aspect, the outer protective layer 25 may preferably be provided with a stain resistant washable fabric, such as a water resistant fabric. In an aspect, the outer protective layer 25 may further comprise a decorative layer, such as a coloured or patterned fabric.

FIG. 4 thus illustrates a cut-away view of a compressible mattress 30. In this embodiment, outer protective layer 25 would be the exterior surface of the mattress 30. Inclusion of the outer protective layer 25 is an optional feature of the mattress 30. In an alternate embodiment, the mattress 30 may comprise the perforated foam core 10 and the protective layer 20, in which case the protective layer 20 would be the exterior surface of the mattress 30. In a further embodiment, the mattress 30 may comprise only the perforated foam core 10.

Referring to FIG. 5, the compressible mattress 30 of FIG. 4 is illustrated after insertion within a packaging 35 in the form of a flexible air tight vessel such as a plastic bag. In the embodiment of FIG. 5, the packaging 35 comprises a clear-walled plastic bag with an opening 40 at an opening end 45 of the packaging 35. The arrows depicted in FIG. 5 indicate a direction of compression to be applied to compress the mattress 30.

Referring to FIG. 6, the mattress 30 within packaging 35 of FIG. 5 is illustrated in place between the platens 115, 120 of a press 110. In the embodiment, when the action of the press presses the platens 115, 120 together, the mattress 30 is compressed and the packaging 35 is evacuated through the opening 40. After the press 110 has been compressed, the opening end 45 may be sealed, for instance with heat sealing, laser, adhesive, or other known means, to prevent the ingress of air through opening 40 back into the packaging 35.

While the embodiment of FIG. 5 illustrates a single opening 40, the packaging 35 may have a plurality of openings 40. For instance, the packaging 35 may comprise a tube with openings 40 at opposed ends. Alternatively, the packaging may comprise a pair of sheets to be placed around the mattress 30 with openings 40 defined by the mating edges of the sheets. It has been found, however, convenient to select a packaging 35 that comprises a bag with a single opening 40 for ease of assembly and sealing.

Referring to FIG. 7, after sealing the opening end 45, the press may be released and the compressed packaged mattress 32 extracted. The compressed packaged mattress 32 comprising the mattress 30 after compression, and sealed within the sealed air tight packaging 35 which maintains the mattress 30 in its compressed form. Referring to FIG. 8, the compressed packaged mattress 32 may be further compacted, for instance by rolling as shown or folding, and placed within a container 50. The container 50 maintaining the compressed packaged mattress 32 in its compacted form (i.e. rolled form or folded form).

In the embodiment of FIG. 9, the container 50 comprises a bag or sleeve into which the rolled compressed packaged mattress 32 may be inserted to produce a packaged, rolled, compressed, and packaged mattress 32. The container 50 maintaining the compressed packaged mattress 32 in its rolled form for transport, display and retail. In some embodiments the container 50 may comprise a decorative layer

A portion of the disclosure of this patent document contains material which is or may be subject to one or more of copyright, design patent, industrial design, or unregistered design protection. The rights holder has no objection to the reproduction of any such material as portrayed herein through facsimile reproduction of the patent document or patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all rights whatsoever. 

1. A compressible mattress comprising: a foam core in a shape of mattress, said foam core perforated by at least one hole through a face of the core.
 2. The compressible mattress of claim 1 wherein the at least one hole comprises a plurality of holes through the face of the mattress.
 3. The compressible mattress of claim 2 wherein the plurality of holes are axially aligned with one another.
 4. The compressible mattress of claim 2 wherein the plurality of holes are even distributed across the face of the mattress.
 5. The compressible mattress of claim 2 wherein the plurality of holes are each perforated clear through opposed faces of the mattress.
 6. The compressible mattress of claim 2 wherein a diameter of each of the plurality of holes is within a diameter range of 8 mm-20 mm.
 7. The compressible mattress of claim 6 wherein the diameter range is between 10 mm-15 mm.
 8. The compressible mattress of claim 7 wherein the diameter range is between 12-13 mm.
 9. The compressible mattress of claim 7, wherein the mattress comprises a crib mattress having face dimensions of about 27 ⅝″-28 ⅝″ wide and 51 ¾″-53″ long, and wherein the mattress has a thickness between a range of 4″-6″ thick, and wherein the plurality of holes are bored through the thickness with openings on both opposed faces.
 10. The compressible crib mattress of claim 9 wherein the plurality of holes comprises between 80 to 160 holes evenly spaced across the faces of the mattress.
 11. The compressible mattress of claim 1, further comprising a protective layer surrounding the foam core, the protective layer comprising a waterproof, air permeable membrane.
 12. The compressible mattress of claim 11, wherein the protective layer is sealed around the foam core.
 13. The compressible mattress of claim 11, further comprising an air permeable outer protective layer over the protective layer.
 14. The compressible mattress of claim 13, wherein the outer protective layer comprises a decorative layer.
 15. The compressible mattress of claim 14, wherein the outer protective layer is removably secured over the protective layer.
 16. A compressed mattress comprising the mattress of claim 1, after compression into a compressed state and secured within a sealed, airtight packaging.
 17. A compacted mattress comprising the compressed mattress of claim 16, compacted and secured in the compact state by a container.
 18. The compacted mattress of claim 17 wherein the container comprises one of a plastic bag, a cardboard box, and a fastener.
 19. A method of manufacturing a compressed mattress, comprising: boring a plurality of holes through a thickness of a foam core to produce a mattress; inserting the mattress into a flexible, air tight packaging; compressing the packaging and the mattress; and, sealing an open end of the flexible, air tight packaging to produce a compressed mattress sealed within the flexible, air tight packaging in a compressed form.
 20. The method of claim 19, wherein the method further comprises: after boring the plurality of holes, wrapping the bored foam core with a waterproof air permeable protective layer, and sealing the waterproof air permeable protective layer around the bored foam core to produce the mattress.
 21. The method of claim 20, wherein the method further comprises: after sealing the waterproof air permeable protective layer around the bored foam core, wrapping and securing an outer protective layer over the protective layer to produce the mattress.
 22. The method of claim 19, further comprising: compacting the compressed mattress, and securing the compacted compressed mattress within a second packaging.
 23. The method of claim 19, wherein the compressing comprises: inserting the flexible, air tight packaging containing the mattress between platens of a press; pressing the platens together to compress the packaging and the mattress; and, wherein the sealing comprises: sealing the open end before releasing the platens and withdrawing the sealed packaging containing the compressed mattress from the press. 